Systems and methods for dispensing items

Abstract

The present disclosure provides systems and methods for product handling and dispensing. In one aspect, the present disclosure provides a system comprising a plurality of storage units for storing one or more trays comprising one or more items; one or more dispense conveyors for lifting and dispensing at least one of the one or more items into one or more receiving units; and a shuttle comprising one or more tray retrieval mechanisms, wherein the shuttle is (a) movable relative to the plurality of storage units and (b) configured to (i) pick at least one tray of the one or more trays using the one or more tray retrieval mechanisms and (ii) transport the at least one tray to the one or more dispense conveyors.

1 . A product handling system comprising:
 a first tray comprising:
 a first opening; and 
 a first set of supports:
 arranged over the first opening; 
 defining a first set of lanes within the first tray; and 
 configured to support product units within the first set of lanes; and 
 
   a first dispensing unit:
 configured to transiently receive the first tray; and 
 comprising a first set of dispensing arms configured to:
 pass through the first opening of the first tray toward the first set of supports; 
 elevate through a first lane, in the first set of lanes and defined between a first pair of supports in the first set of supports to lift a first row of product units, stored in the first lane between the first pair of supports, above the first lane; and 
 drive the first row of product units forward toward a first receiving area. 
 
   
     
     
         2 . The product handling system of  claim 1 , further comprising a controller configured to:
 receive a customer order specifying a set of product types; and   in response to the customer order specifying a first quantity of product units of a first product type stored in the first lane:
 trigger a mobile robotic system to maneuver to the first receiving area; and 
 trigger the first set of dispensing arms to:
 elevate through the first lane to lift the first row of product units above the first lane; and 
 drive the first row of product units forward toward the first receiving area to dispense the first quantity of product units of the first product type into a container transiently loaded into the mobile robotic system occupying the first receiving area. 
 
   
     
     
         3 . The product handling system of  claim 1 , wherein the first tray is configured to:
 in a first configuration:
 transiently store the first row of product units of a first product type in the first lane, the first product type comprising a canned good; and 
 transiently store a second row of product units of a second product type in a second lane, in the first set of lanes, adjacent the first lane, the second product type comprising a boxed good; and 
   in a second configuration:
 transiently store a third row of product units of a third product type in the first lane, the third product type comprising loose produce; and 
 transiently store a fourth row of product units of a fourth product type in the second lane, the fourth product type comprising a bagged product. 
   
     
     
         4 . The product handling system of  claim 1 :
 wherein the first set of dispensing arms is configured to dispense product units, in the first row of product units of a first product type, stored in the first lane in a first configuration of the first tray; and   wherein the first dispensing unit further comprises a second set of dispensing arms configured to:
 pass through the first opening of the first tray toward the first set of supports; 
 elevate through the first lane to lift a second row of product units above the first lane, the second row of product units of a second product type different from the first product type and stored in the first lane between the first pair of supports in a second configuration of the first tray; and 
 drive the second row of product units forward toward the first receiving area. 
   
     
     
         5 . The product handling system of  claim 4 :
 wherein each arm in the first set of dispensing arms comprises a bead chain;   wherein the first set of dispensing arms is configured to dispense product units of the first product type comprising a boxed good; and   wherein the second set of dispensing arms comprises a set of rollers configured to dispense product units of the second product type comprising loose produce.   
     
     
         6 . The product handling system of  claim 1 :
 wherein the first dispensing unit is arranged within a first dispense station;   wherein the first set of dispensing arms is configured to dispense product units of a first product type exhibiting a first product geometry; and   further comprising:
 a second tray comprising:
 a second opening; and 
 a second set of supports:
 arranged over the second opening; 
 defining a second set of lanes within the second tray; and 
 configured to support product units within the second set of lanes; and 
 
 
 a second dispensing unit:
 arranged within a second dispense station adjacent the first dispense station; 
 configured to transiently receive the second tray; and 
 comprising a second set of dispensing arms configured to:
 pass through the second opening of the second tray toward the second set of supports; 
 elevate through a second lane, in the second set of lanes and defined between a second pair of supports in the second set of supports, to lift a second row of product units of a second product type, stored in the second lane between the second pair of supports, above the second lane, the second product type exhibiting a second product geometry different from the first product geometry; and 
 drive the second row of product units forward toward a second receiving area. 
 
 
   
     
     
         7 . The product handling system of  claim 6 :
 wherein the first set of dispensing arms is configured to dispense product units of the first product type comprising a boxed good; and   wherein the second set of dispensing arms is configured to dispense product units of the second product type comprising loose produce.   
     
     
         8 . The product handling system of  claim 1 , further comprising:
 a tray storage rack:
 comprising a set of slots; and 
 configured to transiently store the first tray in a first slot in the set of slots; and 
   a tray routing conveyor configured to:
 in response to detecting an assignment of the first receiving area to the first tray:
 retrieve the first tray from the first slot in the tray storage rack; and 
 locate the first tray within a first dispense station housing the first dispensing unit. 
 
   
     
     
         9 . The product handling system of  claim 1 , wherein the first set of dispensing arms is configured to:
 pass through the first opening of the first tray toward the first lane;   laterally expand to a first separation distance corresponding to a first width of the first row of product units, of a first product type, stored in the first lane;   pass through a second opening of the first tray toward a second lane, in the first set of lanes, defined by the first set of supports;   laterally retract to a second separation distance, less than the first separation distance, corresponding to a second width of a second row of product units, of a second product type, stored in the second lane, the second product type narrower than the first product type;   elevate through the second lane to lift the second row of product units above the second lane; and   drive the second row of product units forward toward the first receiving area.   
     
     
         10 . The product handling system of  claim 1 , wherein the first set of dispensing arms is configured to dispense the first row of product units forward toward a container transiently occupying the first receiving area, the container retrievable from a customer pickup bay by a customer. 
     
     
         11 . The product handling system of  claim 1 :
 further comprising a mobile robotic system configured to:
 receive product units of product types specified in a customer order; and 
 maneuver to the first receiving area in response to the customer order specifying a first quantity of product units of a first product type stored in the first lane; and 
   wherein the first set of dispensing arms is configured to drive the first row of product units forward toward the first receiving area to dispense the first quantity of product units of the first product type into the mobile robotic system occupying the first receiving area.   
     
     
         12 . The product handling system of  claim 1 , wherein the first set of dispensing arms is configured to:
 maneuver to a first position aligned with the first lane;   lift the first row of product units, of a first product type stored in the first lane, above the first lane;   drive the first row of product units forward by a first distance based on a first dimension of the first product type to dispense a first product unit of the first product type into the first receiving area;   maneuver to a second position aligned with a second lane, in the first set of lanes, defined between a second pair of supports, in the first set of supports, in the first tray;   elevate through the second lane to lift a second row of product units, stored in the second lane between the second pair of supports, above the second lane, the second row of product units of a second product type different from the first product type; and   drive the second row of product units forward by a second distance based on a second dimension of the second product type to dispense a second product unit of the second product type into the first receiving area, the second dimension greater than the first dimension, the second distance greater than the first distance.   
     
     
         13 . The product handling system of  claim 1 , further comprising a controller configured to:
 receive a customer order specifying a set of product types;   for a first product type in the set of product types specified in the customer order:
 identify the first tray, in a set of trays, storing the first row of product units of the first product type; 
 retrieve a current location of the first tray; and 
 assign the first receiving area to the first tray for dispensation of a product unit of the first product type from the first tray; 
   trigger a mobile robotic system to maneuver to the first receiving area; and   trigger the first set of dispensing arms to:
 elevate through the first lane to lift the first row of product units above the first lane; and 
 drive the first row of product units forward toward the first receiving area to dispense product units of the first product type into a container transiently loaded into the mobile robotic system occupying the first receiving area. 
   
     
     
         14 . A product handling system comprising:
 a first tray comprising a first set of supports:
 defining a first set of lanes within the first tray; and 
 configured to support product units within the first set of lanes; 
   a first dispensing unit:
 configured to transiently receive the first tray; and 
 comprising a first set of dispensing arms configured to:
 elevate through a first lane, in the first set of lanes and defined between a first pair of supports in the first set of supports, toward the first set of supports to lift a first row of product units, stored in the first lane between the first pair of supports, above the first lane; and 
 drive the first row of product units forward toward a first receiving area; and 
 
   a controller configured to trigger the first set of dispensing arms:
 to elevate through the first lane toward the first set of supports to lift the first row of product units; 
 to laterally extend forward toward the first receiving area to locate distal ends of the first set of dispensing arms over the first receiving area; and 
 to dispense the first row of product units forward toward the first receiving area. 
   
     
     
         15 . The product handling system of  claim 14 , wherein the first tray is configured to:
 transiently store the first row of product units of a first product type in the first lane; and   transiently store a second row of product units of a second product type in a second lane, in the first set of lanes, adjacent the first lane, the second product type different from the first product type.   
     
     
         16 . The product handling system of  claim 14 , further comprising a mobile robotic system configured to:
 receive product units of product types, specified in a customer order and dispensed by the first dispensing unit, within a container transiently loaded into the mobile robotic system when occupying the first receiving area; and   deliver the container to a storage locker, the container retrievable from the storage locker by a customer.   
     
     
         17 . The product handling system of  claim 14 :
 wherein the first dispensing unit is arranged within a first dispense station;   wherein the first set of dispensing arms is configured to dispense product units, of a first product type exhibiting a first geometry characteristic, from the first tray; and   further comprising:
 a second tray comprising a second set of supports:
 defining a second set of lanes within the second tray; and 
 configured to support product units within the second set of lanes; and 
 
 a second dispensing unit:
 arranged within a second dispense station adjacent the first dispense station; 
 configured to transiently receive the second tray; and 
 comprising a second set of dispensing arms configured to:
 elevate through a second lane, in the second set of lanes and defined between a second pair of supports in the second set of supports, to lift a second row of product units, stored in the second lane between the second pair of supports, above the second lane, the second row of product units of a second product type exhibiting a second geometry characteristic different from the first geometry characteristic; and 
 drive the second row of product units forward toward a second receiving area. 
 
 
   
     
     
         18 . The product handling system of  claim 17 , wherein the controller is configured to:
 receive a customer order specifying a set of product types;   in response to the customer order specifying a first quantity of product units of the first product type stored in the first lane:
 trigger a mobile robotic system to maneuver to the first receiving area; and 
 trigger the first set of dispensing arms to:
 elevate through the first lane to lift the first row of product units above the first lane; and 
 drive the first row of product units forward toward the first receiving area to dispense the first quantity of product units of the first product type into a container transiently loaded into the mobile robotic system occupying the first receiving area; and 
 
   in response to the customer order further specifying a second quantity of product units of the second product type stored in the second lane:
 trigger the mobile robotic system to maneuver to the second receiving area; and 
 trigger the second set of dispensing arms to:
 elevate through the second lane to lift the second row of product units above the second lane; and 
 drive the second row of product units forward toward the second receiving area to dispense the second quantity of product units of the second product type into the mobile robotic system occupying the second receiving area. 
 
   
     
     
         19 . The product handling system of  claim 14 :
 wherein the first tray is configured to transiently store the first row of product units of a first product type in the first lane, the first product type comprising a bagged product; and   wherein the controller is configured to:
 in response to receiving a customer order specifying a first quantity of product units of the bagged product, stored in the first lane:
 trigger a mobile robotic system to maneuver to the first receiving area; and 
 trigger the first set of dispensing arms to:
 elevate through the first lane to lift the first row of product units above the first lane; and 
 drive the first row of product units forward by a distance based on the first quantity of product units and a dimension of the bagged product to dispense the first quantity of product units of the bagged product into the mobile robotic system occupying the first receiving area. 
 
 
   
     
     
         20 . A product handling system comprising:
 a tray comprising:
 a base; and 
 a set of supports:
 arranged over the base; 
 defining a set of lanes within the tray; and 
 configured to support product units within the set of lanes; and 
 
   a dispensing unit configured to:
 transiently receive the tray; 
 pass through the base of the tray toward the set of supports; 
 elevate through a lane, in the set of lanes and defined between a pair of supports in the set of supports, to lift a row of product units, stored in the lane between the pair of supports, above the lane; and 
 drive the row of product units forward toward a receiving area.